Formula Student Prototype – Component Design & DFM

Comprehensive 3D mechanical modeling, structural component design, and fabrication support for a high-performance Formula Student prototype. Working as a core engineer on the project, my responsibilities centered around translating complex vehicle kinematics and spatial packaging constraints into highly rigid, manufacturable components using SolidWorks. A major focus of this work involved the detailed design of the vehicle's mechanical and unsprung assemblies. This included developing multi-part suspension geometries, custom CNC-machined uprights, and 3D-printed brackets engineered to safely transfer dynamic load paths while adhering to strict weight-reduction targets. Every component was modeled with real-world assembly tolerances and tool access clearances in mind to ensure seamless integration on the shop floor. Furthermore, the project required deep integration of Design for Manufacturing (DFM) principles across multiple fabrication methods. I optimized complex structural components for precise multi-axis CNC machining, ensuring efficient toolpaths and minimal setups. I also handled intricate casting designs, specifically adapting complex cross-sectional geometries—such as thin-walled volutes where traditional risers could not be utilized—to ensure successful manufacturing without compromising internal flow or structural integrity. Ultimately, these mechanical systems were engineered to withstand the extreme, repetitive kinetic stresses experienced across rigorous dynamic testing and competition events. The result is a portfolio piece that showcases a proven ability to balance aggressive performance requirements with practical, cost-effective manufacturing realities.